Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 11

2B-6

Chapter 2 Part B V6 engine

5.8 Exhaust manifold-to-exhaust system joint (upper arrow) and

cross-over pipe (lower arrow)

to remove the rear manifold heat shield, dis-
connect the oxygen sensor wiring harness at
the connector. In order to remove the front
manifold heat shield, the alternator upper
bracket must be removed.
4

To make removal easier, apply penetrat-

ing oil to the exhaust manifold and manifold-

to-pipe fasteners.

5

Working under the vehicle, remove the

exhaust manifold cross-over pipe.
6

Disconnect the oxygen sensor wiring

harness at the connector.
7

If you are removing the rear exhaust

manifold (near the firewall), remove the power
steering pump bracket (see Chapter 10).
8

If you are removing the rear exhaust

manifold (near the firewall), detach the
exhaust system from the manifold (see

illus-

tration). Note: It may be necessary to
remove, or partially remove, the exhaust sys-

tem to facilitate rear manifold removal (see
Chapter 4 if necessary).

9

Unscrew the mounting nuts, remove the

exhaust manifold and gasket (see illustra-
tion).

10

Using a wire brush, clean the exhaust

manifold studs, replacing any that show

thread damage.

11

Using a scraper, remove all traces of

gasket material from the exhaust manifold,
cylinder head, and exhaust pipe mating sur-
faces and inspect them for wear and cracks.
Caution: When removing gasket material
from any surface, especially aluminum, be
very careful not to scratch or gouge the gas-
ket surface. Any damage to the surface may a
leak after reassembly. Gasket removal sol-
vents are available from auto parts stores and
may prove helpful.

12

Using a precision straightedge and

feeler gauge, check the exhaust manifold
gasket surfaces for warpage. Check the sur-
face on the cylinder head also. If the warpage
on any surface exceeds the limits listed in
this Chapter's Specifications, the exhaust
manifold and/or cylinder head must be
replaced or resurfaced by an automotive
machine shop.

Installation

13 Install the new exhaust gasket(s) onto

5.9 Exhaust manifold mounting nuts (arrows) (front manifold

shown, heat shield removed)

6.4a To keep the crankshaft from turning,

insert a large screwdriver or bar through

the opening in the damper/pulley and

wedge it against the engine block, then

loosen the bolt with a socket and

breaker bar

the cylinder head.
14

Apply Loctite No. 271 to the exhaust

manifold mounting stud threads.
15 Install the manifold, washers and nuts.
Tighten the nuts in three stages, working
from the center out, to the torque listed in this
Chapter's Specifications.
16

The remaining installation steps are the

reverse of removal. Install a new gasket(s)
between the exhaust manifold and exhaust
pipe(s). Tighten the nuts to the torque listed
in this Chapter's Specifications.
17

Run the engine and check for exhaust

leaks.

6

Timing belt - removal, inspection
and installation

Caution: If the timing belt failed with the
engine operating, damage to the valves may

have occurred. Perform an engine compres-
sion check after belt replacement to deter-
mine if any valve damage is present.

6.4b Remove the damper/pulley from

the crankshaft

Removal

Refer to illustrations 6.4a, 6.4b, 6.6, 6.7,
6.11a, 6.11b, 6.12 and 6.13
Caution: Do not turn the crankshaft or
camshafts after the timing belt has been
removed, as this will damage the valves from
contact with the pistons. Do not try to turn
the crankshaft with the camshaft sprocket
bolt(s) and do not rotate the crankshaft coun-
terclockwise as viewed from the timing belt
end of the engine.

Note: In order to perform this procedure, a

special tool is required to properly tension the
timing belt. The manufacturers tool number is

"MD 998767" and may be available from a

dealership parts department or directly from
Miller Special Tools (phone no. 800-801-
5420).

1

Position the number one piston at Top

Dead Center (see Chapter 2C).

2

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
3

Remove the drivebelts (see Chapter 1).

4

Loosen the large bolt in the center of the

crankshaft damper/pulley. It might be very
tight, to break it loose insert a large screw-
driver or bar through the opening in the

pulley

to keep the crankshaft stationary, then

Chapter 2 Part B V6 engine

2B-7

6.6 Timing belt cover bolt locations

6.11a Verify that the camshaft sprocket timing marks are aligned

with their respective marks on the rear timing belt covers

6.11b Crankshaft timing belt sprocket and oil pump housing

timing marks (arrows)

RIGHT CAM

SPROCKET

ALIGN TIMING

MARKS

LEFT CAM

SPROCKET

L.

6.7 Remove the bolts (arrows) that attach the timing belt lower

cover to the engine

2B

6.12 Paint an arrow on the timing belt in
the direction of rotation (clockwise) so it

may be reinstalled in the same direction

6.13 Timing belt tensioner mounting

bolts (arrows)

loosen the bolt with a socket and breaker
bar. Remove the bolt, washer and dam-
per/pulley from the crankshaft (see illustra-
tions).
5

After removing the crankshaft pulley,

reinstall the crankshaft bolt using an appro-
priate spacer (this will enable you to turn the
crankshaft later).
6

Remove the upper-left timing belt cover

(see illustration).
7

Remove the lower timing belt cover (see

illustration).
8

Detach the power steering pump

bracket from the engine (see Chapter 10 if
necessary).
9

Remove the upper-right timing belt

cover (see illustration 6.6).
10

Remove the right (passenger side)

engine mount and the mounting bracket from
the engine (see Section 17). Note:

Make

sure

the engine is supported with

a

floor

jack

placed under the oil pan. Place a wood

block

on the

jack head

to prevent the floor jack from

denting or damaging the oil pan.
11

Make sure the timing marks on the

crankshaft sprocket and camshaft sprockets
align with their respective marks before
removing the timing belt (see illustrations).

12 If you plan to reuse the timing belt, paint
an arrow on it to indicate the direction of
rotation (clockwise) (see illustration).
13

Loosen the timing belt tensioner mount-

ing bolts and then remove the tensioner (see
illustration). Note: The tensioner piston will

extend when the assembly is removed.
14

Carefully slip the timing belt off the

sprockets and set it aside. If you plan to
reuse the timing belt, place it in a plastic bag
- do not allow the belt to come in contact
with any type of oil or water as this will greatly
shorten belt life.

2B-8

Chapter 2 Part B V6 engine

6.18 Carefully inspect the timing belt for damage or wear -

bending it backwards will often make defects more apparent

6.24 Using a vise (lined with soft-jaws), compress the timing belt

tensioner piston until the holes in the housing and piston align.

Then place a small Allen wrench (arrow) or drill bit, through the

holes to keep the piston in position for installation

6.25 Using special tool MD 998767 attached to a torque wrench,

apply 39 in-lbs of torque (in a counterclockwise direction) to the

tensioner pulley, then move the tensioner unit up against the

tensioner pulley bracket and tighten the tensioner mounting bolts

to the torque listed in this Chapter's Specifications

6.22 Binder clips (arrows) can be used to retain the timing belt in

position on the camshaft sprockets during installation

Inspection

Refer to illustration 6.18

15

With the timing belt covers removed,

now is a good time to inspect the front
crankshaft and camshaft seals for leakage. If
leakage is evident, replace the them (see
Section 7 and 8, respectively).
16 Inspect the water pump for evidence of
leakage (usually indicated by a trail of wet or
dried coolant). Check the pulley for excessive
radial play and bearing roughness. Replace if
necessary (see Chapter 3).
17

Rotate the tensioner pulley and idler pul-

ley by hand and move them side-to-side to
detect bearing roughness and/or excessive
play. Visually inspect all timing belt sprockets
for any signs of damage or wear. Replace as
necessary.
18 Inspect the timing belt for cracks, sepa-
ration, wear, missing teeth and oil contamina-

tion (see illustration). Replace the belt if it's

in questionable condition or the engine
mileage is close to that referenced in the

Maintenance Schedule (see Chapter 1).

19

Check the timing belt tensioner unit for

leaks or any other obvious damage, replace if
necessary.

Installation

Refer to illustrations 6.22, 6.24, 6.25 and 6.27
20

Confirm that the timing marks on both

camshaft sprockets are aligned with their

respective marks on the rear timing belt cov-

ers (see illustration 6.11a). Reposition the
camshafts if required. Caution: if it is neces-
sary to rotate the camshafts to align the tim-
ing marks, first rotate the crankshaft slightly
counterclockwise (three notches on the
sprocket) to ensure the valves do not contact
the pistons.
21

Position the crankshaft sprocket with

the timing marks aligned (see illustration
6.11b).
22 Install the timing belt as follows; first
place the belt onto the right camshaft
sprocket (the one towards the rear of the
vehicle) and clamp it to the sprocket, while
maintaining tension on the belt, wrap it under
the water pump pulley and place it onto the
left sprocket camshaft sprocket. Secure the
timing belt to the left camshaft sprocket (see
illustration). Continue to wrap the timing belt
over the idler pulley, around the crankshaft
sprocket and finishing with the tensioner pul-
ley. Remove the clamps from the camshaft

sprockets.
23

Make sure the timing belt is tight

between the left camshaft sprocket and the
crankshaft sprocket, all the slack is at the

tensioner pulley and all the timing marks are

aligned.
24

Before installation, the timing belt ten-

sioner piston must be compressed into the

tensioner housing. Place the tensioner in a
vise so the surface with the pin hole is facing

up. Slowly compress the tensioner using the

vise, then install an appropriate size Allen
wrench or drill bit through the body and into
the piston to retain the piston in this position

(see illustration). Remove the tensioner from

the vise.
25

Using the special tool "MD 998767"

engaged in the tensioner pulley, have an
assistant apply 39 in-lbs of torque in a coun-
terclockwise direction (see illustration).
26

With the torque applied to the tensioner

pulley, install the tensioner assembly. Move

the tensioner up against the tensioner pulley
bracket and tighten the mounting bolts to the
torque listed in this Chapter's Specifications.

Remove the torque wrench and special tool

from the tensioner pulley.

Chapter 2 Part B V6 engine

2B-9

6.27 If the timing belt tension is set

correctly, the tensioner piston retaining

pin (arrow) (an Allen wrench in this case)

can be removed and installed easily

27

Remove the Allen wrench or drill bit

retaining the piston from the tensioner. The

ti ming belt tension is correct when the ten-

sioner piston retaining pin (Allen wrench or

drill bit) can be withdrawn and reinserted eas-

il y (see illustration). Verify that the timing
marks on the camshaft sprockets and

crankshaft sprocket are still aligned with their

-respective ti ming marks (see illustrations
6.11a and 6.11b).

28

Using the bolt in the center of the

crankshaft

sprocket,

slowly

turn

the

crankshaft clockwise two complete revolu-
tions. Caution: If you feel strong resistance
while turning the crankshaft - STOP, the
valves may be hitting the pistons from incor-
rect valve timing. Stop and re-check the valve
timing. Note: The camshafts and crankshaft
sprocket marks will align every two revolu-
tions of the crankshaft. Recheck the align-

ment of the timing marks (see illustrations

6.11a and 6.11b). If the marks do not align

properly, remove the timing belt tensioner,

slip the belt off the camshaft sprockets,
realign the marks, reinstall the belt and ten-
sioner, then check the alignment again.
29

After crankshaft rotation, recheck the

ti ming belt tension by inserting the tensioner
piston retaining pin (Allen wrench or drill bit)
back into the tensioner. If the retaining pin
cannot be inserted and withdrawn freely,
readjust the timing belt tension and repeat
Steps 24 through 29.
30

The remaining installation steps are the

reverse of removal. Tighten the crankshaft
damper/pulley bolt to the torque listed in this
Chapter's Specifications.

7

Crankshaft front oil seal -
replacement

Refer to illustrations 7.2, 7.3 and 7.5
Caution: Do not rotate the camshafts or
crankshaft when the timing belt is removed or
damage to the engine may occur.

7.2 After removing the timing belt

sprocket, remove the Woodruff key

(arrow) from the crankshaft

1

Remove the timing belt (see Section 6).

2

Remove the crankshaft timing belt

sprocket using a gear puller. Remove the
Woodruff key from the crankshaft keyway
(see illustration).
3

Wrap the tip of a small screwdriver with

vinyl tape. Carefully use the screwdriver to
pry the seal out of its bore (see illustration).
Take care to prevent damaging the oil pump
assembly, the crankshaft and the seal bore.
4

Thoroughly clean and inspect the seal

bore and sealing surface on the crankshaft.
Minor imperfections can be removed with
fine emery cloth. If there is a groove worn in
the crankshaft sealing surface (from contact
with the seal), installing a new seal will proba-
bly not stop the leak.
5

Lubricate the new seal with engine oil

and using a hammer and the appropriate size
socket, drive the seal into the bore until it's
flush with the oil pump housing (see illustra-
tion).
6

Install the Woodruff key into the slot in

the crankshaft. Place the crankshaft timing
belt sprocket onto the crankshaft with the
ti ming belt retaining lip facing inward (toward
the engine).
7

The remaining installation steps are the

reverse of removal. Tighten the crankshaft
pulley bolt to the torque listed in this Chap-
ter's Specifications.
8

Start the engine and check for oil leaks.

8

Camshaft oil seal - replacement

Refer to illustrations 8.3, 8.4, 8.6a and 8.6b

Caution: Do not rotate the camshafts or

crankshaft when the timing belt is removed or
damage to the engine may occur.

1

Remove the timing belt (see Section 6).

2

Rotate the crankshaft counterclockwise

until the crankshaft sprocket is three notches
BTDC. This will prevent engine damage if the
camshaft sprocket is inadvertently rotated

during removal.
3

While keeping the camshaft from rotat -

7.3 Using a hooked tool or screwdriver,

carefully pry the crankshaft front seal out

of its bore - DO NOT nick or scratch the

crankshaft or seal bore

7.5 Lubricate the new seal with clean

engine oil and drive it into place using a

hammer and socket

8.3 To hold the camshaft while removing

the sprocket bolt, use an old piece of

ti ming belt wrapped around the sprocket

and a chain wrench as shown

ing, remove the camshaft sprocket bolt. Then
using two large screwdrivers, lever the
sprocket off the camshaft. Note: A strap-type

damper/pulley holder tool is available at most
auto parts stores and is recommended for

2B

2B-10

Chapter 2 Part B V6 engine

8.4 Using a hooked tool or screwdriver,

carefully pry the camshaft seal out of the

bore - DO NOT nick or scratch the

camshaft or seal bore

this procedure, however, if you are not going
to reuse the old timing belt, you can wrap a

piece of it around the sprocket and use a
chain wrench to hold the sprocket in place as
shown (see illustration).
4

Carefully pry out the camshaft oil seal

using a small hooked tool or screwdriver (see
illustration). Don't scratch the bore or dam-
age the camshaft in the process (if the

camshaft is damaged, the new seal will end

up leaking).

5

Clean the bore and coat the outer edge

of the new seal with engine oil or multi-pur-

pose grease. Also lubricate the seal lip.

6

Using a socket with an outside diameter

slightly smaller than the outside diameter of
the seal and a hammer (see illustration),
carefully drive the new seal into the cylinder
head until it's flush with the face of the cylin-
der head. If a socket isn't available, a short
section of pipe will also work. Note: If engine
location makes it difficult to use a hammer to
install the camshaft seal, fabricate a seal
installation tool from a piece of pipe cut to the
appropriate length, a bolt and a large washer
(see illustration). Place the section of pipe
over the seal and thread the bolt into the
camshaft. The seal can now be pressed into
the bore by tightening the bolt.
7

Install the camshaft sprocket, aligning

the pin in the camshaft with the hole in the
sprocket. Using an appropriate tool to hold
the camshaft sprocket, tighten the camshaft
sprocket bolt to the torque listed in this
Chapter's Specifications.
8

Install the timing belt (see Section 6).

9

Run the engine and check for oil leaks.

9

Rocker arm and hydraulic valve
lash adjuster assembly -

removal, inspection and
installation

Removal

1

Disconnect the negative battery cable

from the ground stud on the left shock tower

8.6a Using a hammer and the appropriate

size socket, drive the camshaft seal into

the bore until it is flush with the

cylinder head

(see Chapter 5, Section 1).
2

Position the number one piston at Top

Dead Center (see Chapter 2C).
3

Remove the valve cover(s) as required

(see Section 3).
4

Prior to removing the rocker arm shafts,

identify each rocker arm and shaft as to its
proper location (cylinder number and intake
or exhaust). Caution: Do not interchange the

rocker arms onto a different shaft or shaft
assemblies onto a different location as this
could lead to premature wear.
5

Loosen the rocker arm shaft bolts 1/4-

turn at a time, until they can be loosened by

hand, in the reverse order of the tightening

sequence (see illustration 9.17). Completely

loosen the bolts, but do not remove them,
leaving them in place will prevent the assem-
bly from falling apart when it is lifted off the

cylinder head.
6

Lift the rocker arms and shaft assem-

blies from the cylinder head and set them on

the workbench. Note: The hydraulic valve
lash adjusters may become dislodged from
the rocker arms during shaft removal. If
required, secure the adjusters in place with
vinyl tape.
7

Disassemble the rocker arm shaft com-

ponents paying close attention to their posi-
tions. Note: To keep the rocker arms and
related parts in order, it's a good idea to
remove them and put them onto two lengths
of wire (such as unbent coat hangers) in the
same order as they're removed, marking each
wire (which simulates the rocker shaft) as to
which end would be the front of the engine.

Inspection

Refer to illustration 9.8
Note: The valve lash adjuster is an integral

part of each rocker arm and cannot be

replaced separately. If defective, both must
be replaced.
8

Visually check the rocker arms for

excessive wear or damage (see illustration).
Replace them if evidence of wear or damage
is found.
9

Inspect each lash adjuster carefully for

8.6b If the space is too confined to use a

hammer to drive the seal in place,

fabricate a tool using a bolt, washer and

section of pipe. Place the section of pipe
over the seal and thread the bolt into the

camshaft to press the seal into the bore

signs of wear and damage, particularly on the
surface that contacts the valve tip. Use a
small diameter wire to check the oil holes for
restrictions.
10

Since the lash adjusters frequently

become clogged, we recommend replacing
the rocker arm/lash adjuster assembly if you're
concerned about their condition or if the
engine is exhibiting valve "tapping" noises.
11

Inspect all rocker arm shaft compo-

nents. Look for cracks, worn or scored sur-
faces or other damage. Replace any parts

found to be damaged or worn excessively.

Installation

Refer to illustrations 9.14 and 9.17

12

Prior to installation, the lash adjusters

must be partially full of engine oil - indicated
by little or no plunger action when the
adjuster is depressed. If there's excessive
plunger travel, place the rocker arm assembly
into clean engine oil and pump the plunger
until the plunger travel is eliminated. Note: If

the plunger still travels within the rocker arm
when full of oil it's defective and the rocker
arm assembly must be replaced.

13 Install the rocker arms (and springs -
intake shafts only) onto the shafts, making

sure they are reinstalled in their original loca-
tions.

9.8 Visually inspect the hydraulic lash

adjuster and roller (arrows) for damage

and excessive play - check the rocker arm

shaft bore for score marks or

excessive wear

Chapter 2 Part B V6 engine

2B-11

9.14 The intake rocker arm shaft springs (arrows) must be

installed as shown

9.17 Rocker arm shaft bolt TIGHTENING sequence

10 Camshafts - removal, inspection

Note: The camshaft(s) cannot be removed
with the cylinder head(s) installed on the
engine.

Removal

Refer to illustration 10.5
1

Remove the rocker arm shaft assem-

blies (see Section 9).
2

If you are removing the camshaft in the

right (rear) cylinder head, remove the distribu-
tor (see Chapter 5).
3

Remove the cylinder head (see Sec-

tion 12).

4

On the right cylinder head, carefully

withdraw the camshaft from the distributor
opening in the rear of the cylinder head. Cau-

tion: Do not damage the camshaft lobes or
bearing journals during removal. Note: If you
are removing both camshafts, identify each
one as it is removed from the cylinder head
so that it may be installed back in it's original
location.
5

On the left (front) cylinder head, remove

the thrust case from the rear of the cylinder

head and withdraw the camshaft (see illustra-

tion). Caution: Do not damage the camshaft
lobes or bearing journals during removal.

14

On the intake rocker arm shafts, make

sure that the springs are installed on the shaft
in the correct locations (see illustration).

and installation

15

On the right (rear) cylinder head, install

the rocker arm assemblies with the flat at the
end of each rocker arm shaft located at the
ti ming belt end of the engine and positioned
toward their respective valves.

16

On the left (front) cylinder head, install

the rocker arm assemblies with the flat at the
end of each rocker arm shaft located at the
transaxle end of the engine and positioned
toward their respective valves.

17

Tighten the rocker arm shaft bolts in

sequence shown (see illustration) in three
steps to the torque listed in this Chapter's
Specifications.

18

The remaining installation steps are the

r

everse of removal. Run the engine and

check for oil leaks and proper operation.

19

When re-starting the engine after replac-

ing the rocker arm/lash adjusters, the
adjusters will normally make "tapping" noises
due to air in the lubrication system. To bleed
air from the lash adjusters, start the engine
and allow it to reach operating temperature,
slowly raise the speed of the engine from idle
to 3,000 rpm and back to idle over a one
minute period. If, after several attempts, the
adjuster(s) do not become silent, replace the
defective rocker arm/lash adjuster assembly.

6

Remove the camshaft seal(s) from the

cylinder head(s) (see Section 8 if necessary).

Inspection

Refer to illustration 10.10
7

Using a suitable scraper, remove all

traces of gasket material from

all

gasket sur-

faces. Caution: When removing gasket mate-
rial from any surface, especially aluminum, be
very careful not to scratch or gouge the gas-
ket surface. Any damage to the surface may a
leak after reassembly. Gasket removal sol-
vents are available from auto parts stores and
may prove helpful.
8

Thoroughly clean the camshaft(s) with a

rag soaked in lacquer thinner or acetone.
Visually inspect the camshaft(s) for wear
and/or damage to the lobe surfaces, bearing

journals and seal contact surfaces. Visually

inspect the camshaft bearing surfaces in the
cylinder head(s) for scoring and other dam-
age. Cylinder head replacement may be nec-
essary if the camshaft bearing surfaces in the
head are damaged or excessively worn.
9

Replace any component that fails the

above inspections.
10

Using a micrometer, check the camshaft

lobes for excessive wear by measuring the
center of the lobe (the area the rocker arm
roller rides on) and comparing it with the
edges of the lobes (the area the rocker arm

2B

10.5 On the left (front) cylinder head, remove the thrust cover and

carefully withdraw the camshaft

10.10 Check the camshaft lobes for wear with a micrometer

2B-12

Chapter 2 Part B V6 engine

10.13 Measure the camshaft endplay with a dial indicator
positioned on the sprocket end of the camshaft as shown

10.15 Prior to installing the camshaft, lubricate the bearing

journals, thrust surfaces and lobes with engine assembly lube or

clean engine oil

11.5 This is what the air hose adapter that threads into the spark

plug hole looks like - they're readily available from

auto parts stores

roller does not ride on) (see illustration). If
any wear is indicated, check the correspond-
ing rocker arm, replace the camshaft and
rocker arms if necessary.

Camshaft endplay measurement

Refer to illustration 10.13
11

Lubricate the camshaft(s) and cylinder

head bearing journals with clean engine oil.
12

Carefully insert the camshaft into the

cylinder head and install the thrust case or dis-

tributor as applicable. Tighten the bolts to the
torque listed in this Chapter's Specifications.

13 Install a dial indicator set up on the
cylinder head and place the indicator tip on

the camshaft at the sprocket end (see illus-
tration).

14

Using a screwdriver, carefully pry the

camshaft to the rear of the cylinder head until
it stops. Zero the dial indicator and pry the

camshaft forward. The amount of indicator
travel is the camshaft endplay. Compare the
endplay measurement with the tolerance

li sted in this Chapter's Specifications. If the

endplay is excessive, check the camshaft
and cylinder head thrust bearing surfaces for
wear and replace components as necessary.

Installation

Refer to illustration 10.15

15

Very carefully clean the camshaft and

11.7 Use a small magnet (shown) or needle-nose pliers to remove

the valve spring keepers - be careful not to drop them down into

the engine!

bearing journals. Liberally coat the bearing
journals, lobes and thrust bearing surfaces of
the camshaft with engine assembly lube or
engine oil (see illustration).
16

Carefully insert the camshaft into the

cylinder head. On the left side cylinder head,
install the thrust case, using a new 0-ring,
and tighten the bolts to the torque listed in
this Chapter's Specifications.
17 Install a new camshaft oil seal in the
cylinder head (see Section 8).
18 Inspect the cylinder head bolts and
install the cylinder head(s) (see Section 12).

Torque the cylinder head bolts as described

in Section 12.
19 If removed, install the distributor using a
new 0-ring (see Chapter 5). Tighten the
mounting nuts to the torque listed in the
Chapter 5 Specifications.
20

The remaining installation steps are the

reverse of removal. Start the engine and
check for leaks and proper operation.

- replacement

Refer to illustrations 11.5, 11.7, 11.8, 11.13
and 11.15

Note: Broken valve springs and defective

valve stem seals can be replaced without
removing the cylinder heads. Two special
tools and a compressed air source are nor-
mally required to perform this operation, so
read through this Section carefully and rent or
buy the tools before beginning the job.
1

Remove the appropriate valve cover

(see Section 3).
2

Remove the rocker arm assemblies (see

Section 9).
3

Remove the spark plugs from that head

(see Chapter 1 if necessary).
4

Turn the crankshaft until the piston in

the affected cylinder is at Top Dead Center
on the compression stroke (refer to Chap-
ter 2C). If you're replacing all of the valve
stem seals, begin with cylinder number one
and work on the valves for one cylinder at a
ti me. Move from cylinder-to-cylinder follow-
ing the firing order sequence (see this Chap-

ter's Specifications).

5

Thread an adapter into the spark plug

hole (see illustration) and connect an air
hose from a compressed air source to it.

11

Valve springs, retainers and seals

Most auto parts stores can supply the air
hose adapter. Note: Many cylinder compres-

sion gauges utilize a screw-in fitting that may

work with your air hose quick-disconnect fit-
ting.
6

Apply compressed air to the cylinder.

Warning: The piston may be forced down by

Chapter 2 Part B V6 engine

2B-13

11.8 Cut-away view of the valve seal and

spring components

compressed air, causing the crankshaft to
turn suddenly. If the wrench used when posi-
tioning the number one piston at TDC is still

attached to the crankshaft pulley bolt, it could

cause damage or injury when the crankshaft
moves.
7

Stuff clean shop rags into the cylinder

head holes above and below the valves to
prevent parts and tools from falling into the
engine, then use a valve spring compressor
tool to compress the spring. Remove the
keepers with small, needle-nose pliers or a
magnet (see illustration).
8

Remove the spring retainer and valve

spring. Next, using pliers remove the valve
guide seal and then lift off spring seat (see
illustration). Caution: If air pressure fails to
hold the valve in the closed position during
this operation, the valve face and/or seat is

probably damaged. If so, the cylinder head

will have to be removed for additional repair
operations.
9

Wrap a rubber band or tape around the

top of the valve stem so the valve won't fall
into the combustion chamber, then release
the air pressure.
10 Inspect the valve stem for damage.
Rotate the valve in the guide and check the
end for eccentric movement, which would
indicate that the valve is bent.
11

Move the valve up-and-down in the

guide and make sure it doesn't bind. If the
valve stem binds, either the valve is bent or

the guide is damaged. In either case, the

head will have to be removed for repair.
12

Pull up on the valve stem to close the

valve, reapply air pressure to the cylinder to
retain the valve in the closed position, then
remove the tape or rubber band from the
valve stem.
13 Install the valve spring seat. Lubricate

the valve stem with clean engine oil and

place the new valve guide seal. Tap it into
place with deep socket (see illustration).
14 Install the spring in position over the

valve.

15 Install the valve spring retainer. Com-
press the valve spring and carefully position

the keepers in the groove. Apply a small dab
of grease to the inside of each keeper to hold

11.13 Gently tap the new seal onto the

valve guide with a hammer and

deep socket

it in place if necessary (see illustration).
16

Remove the pressure from the spring

tool and make sure the keepers are seated.

17

Disconnect the air hose and remove the

adapter from the spark plug hole. Repeat the
procedure for any other defective valves.
18 Install the rocker arm assemblies (see
Section 9).
19 Install the spark plug and connect the

wire(s).

20 Install the valve cover (see Section 3).
21

Start and run the engine, then check for

oil leaks and unusual sounds coming from

the valve cover area.

12

Cylinder head - removal and
installation

Caution: Allow the engine to cool completely

before beginning this procedure.

Removal

Refer to illustrations 12.11, 12.18, 12.19a and

12.19b
1

Disconnect the negative battery cable

from the ground stud on the left shock tower

(see Chapter 5, Section 1).

2

Position the number one piston at Top

Dead Center (see Chapter 2C).

3

Remove the upper and lower intake

manifolds (see Section 4).

4

Drain the cooling system, remove the

spark plugs and spark plug wires (see Chap-
ter 1). Note: Leave the plug wires attached to
the distributor cap.
5

If you are removing the right (rear) cylin-

der head, remove the distributor (see Chap-
ter 5).
6

Remove the thermostat housing from

the rear of the cylinder heads (see Chapter 3).

7

Remove rocker arm shaft assemblies

(see Section 9).
8

If you are removing the right (rear) cylin-

der head, remove the bolts securing the

power steering reservoir and hoses to the

cylinder head and position them out of the

11.15 Apply a small dab of grease to each

keeper before installation to hold it in

place on the valve stem until the spring

is released

way (see Chapter 10).
9

Disconnect the power steering pump

bracket from the engine (see Chapter 10).
10

Remove the exhaust manifold(s) (see

Section 5).
11

If you are removing the left (front) cylin-

der head, remove the EGR solenoid/trans-
ducer assembly and EGR valve from the rear
of the cylinder head (see illustration).
12

Remove the timing belt (see Section 6).

13

Remove camshaft sprocket(s) (see Sec-

tion 8).
14

Clearly label and disconnect any hoses,

li nes, brackets or electrical connections that
may interfere with cylinder head removal.
15

Loosen the cylinder head bolts, 1/4-turn

at a time, in the reverse order of the tighten-
ing sequence (see illustration 12.24) until
they can be removed by hand.
16

Carefully lift the cylinder head straight

up and place it on wood blocks to prevent
damage to the sealing surfaces. If the head
sticks to the engine block, dislodge it by
placing a wood block against the head cast-

12.11 EGR solenoid/transducer assembly

(upper arrow) and EGR valve (lower arrow)

- remove the EGR solenoid/transducer

and engine lifting bracket as an assembly

2B